A virtual test method for quartz lamp radiation heating

Abstract

The present invention relates to a quartz lamp radiation heating virtual test method, which belongs to the field of virtual test technology and solves the problem that the existing heating virtual test cannot accurately feedback the real heating situation. A quartz lamp radiation heating virtual test method includes the following steps: Step 1: Establishing a simulation model of a heating control system; Step 2: Establishing a simulation model of a test piece heating calculation; Step 3: Establishing real-time data exchange between Matlab and Abaqus; Step 4: Performing a thermal environment test on the test piece. The quartz lamp radiation heating virtual test method of the present invention uses computer simulation technology to virtually debug the heater design and control system parameter design of the test piece thermal test, which can estimate the thermal response parameters of the structure surface, control the matching of input and output conditions, and ensure the smooth completion of the thermal test.

Description

Technical Field

[0001] The invention belongs to the technical field of virtual experiments, and in particular relates to a quartz lamp radiation heating virtual experiment method. Background Art

[0002] Aircraft face very harsh thermal environments when flying at high speeds, which puts severe tests on the structure of the aircraft and the electronic equipment in the cabin. In engineering practice, ground thermal tests are carried out to simulate the thermal environment of flight in the sky to test whether the thermal protection and thermal matching performance design of the high-speed aircraft structure meet the use requirements and whether the electronic equipment can work normally. Quartz lamps are often used as heating elements for radiation heating in structural thermal tests. Quartz lamps have small thermal inertia, are easy to control electrically, and are very suitable for the transient characteristics of aerodynamic heating. At the same time, they are small in size and high in power density, and can be assembled into heaters of different sizes and shapes. They are suitable for both large-scale full-size structural thermal tests and small tests. They have good adaptability to test pieces with complex shapes and structures and can meet most structural thermal test requirements.

[0003] During thermal tests, since most test pieces cannot be heated repeatedly, only a limited number of low-temperature tests can be performed before formal testing. However, the material's physical properties and state will change under heating conditions, which may also cause damage to the test piece. Therefore, in order to ensure the smooth completion of the test, the quartz lamp radiation heating virtual test method can be used to estimate the physical test in advance, which can predict and guide the thermal environment ground simulation test.

[0004] The heating process of the quartz lamp radiation heating test is controlled by the feedback of the heating system, and the test system usually includes multiple groups of quartz lamps, each of which is independently controlled. Traditional quartz lamp radiation heating simulation usually only simulates the radiation heating, and rarely considers the real feedback control process, resulting in the virtual test cannot accurately feedback the real heating situation. Summary of the invention

[0005] In view of the above analysis, the present invention aims to provide a quartz lamp radiation heating virtual test method to solve the problem that the existing heating virtual test cannot accurately feedback the actual heating situation.

[0006] The purpose of the present invention is mainly achieved through the following technical solutions:

[0007] A quartz lamp radiation heating virtual test method comprises the following steps:

[0008] Step 1: Establish a simulation model of the heating control system;

[0009] Step 2: Establish a simulation model for the heating calculation of the test piece;

[0010] Step 3: Establish real-time data exchange between Matlab and Abaqus;

[0011] Step 4: Perform thermal environment test on the test piece.

[0012] Furthermore, in step 1, the simulation of the heating control system is implemented in Matlab, and the simulation model of the heating control system is built using Matlab\Simulink.

[0013] Furthermore, the input of the simulation model of the heating control system includes the desired surface temperature of the test piece, the control parameters, and the surface temperature of the test piece calculated in real time by Abaqus.

[0014] Further, the output of the simulation model of the heating control system is heater power.

[0015] Furthermore, in step 4, the following steps are specifically included:

[0016] Step 4.1: Enter the heater resistance in Abaqus.

[0017] Step 4.2: Establish the test model of the quartz lamp assembly and the test piece, and generate the Abaqus calculation master file;

[0018] Step 4.3: Identify the thermal environment test system in Matlab;

[0019] Step 4.4: Select the control type;

[0020] Step 4.5: Import the expected test piece surface temperature, set the virtual test time, and start the simulation calculation.

[0021] Furthermore, in step 4.2, when establishing the quartz lamp assembly model, the model is established using the planar heat transfer shell unit DS4 according to the length and width of the filament and is placed according to the test position.

[0022] Furthermore, in step 4.2, when establishing the test piece model, a grid model is established using a plane heat transfer shell unit DS4 according to the actual geometric structure of the test piece, and a control point is taken in each heated area to monitor its temperature.

[0023] Furthermore, in step 4.3, the transfer function of the system is identified, the required data is the existing data or the data calculated by Abaqus, the input data is the heater power, and the output data is the surface temperature of the test piece.

[0024] A virtual test method for quartz lamp radiation heating of a titanium alloy plate uses the test method described in the above technical solution, including a steady-state test and a transient test.

[0025] Furthermore, in the transient test, a set of desired temperatures is set, and the power of the heater is adjusted in real time using PI feedback control to achieve control of the surface temperature of the test piece.

[0026] The present invention can achieve at least one of the following beneficial effects:

[0027] (1) The quartz lamp radiation heating virtual test method of the present invention uses computer simulation technology to virtually debug the heater design and control system parameter design of the test piece thermal test, which can estimate the thermal response parameters of the structure surface, control the matching of input and output conditions, and ensure the smooth completion of the thermal test.

[0028] (2) The quartz lamp radiation heating virtual test method of the present invention has a predictive and guiding role in the thermal environment ground simulation test, which can reduce the test cost and shorten the test cycle. At the same time, it can also realize thermal environment simulation beyond the existing thermal environment ground simulation capabilities, providing a basis for product development, thereby accelerating product development progress, improving product quality, and reducing development costs.

[0029] In the present invention, the above-mentioned technical solutions can also be combined with each other to achieve more preferred combination solutions. Other features and advantages of the present invention will be described in the subsequent description, and some advantages can become obvious from the description, or can be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained through the contents particularly pointed out in the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The drawings are only for the purpose of illustrating particular embodiments and are not to be considered limiting of the present invention. Like reference symbols denote like components throughout the drawings.

[0031] Figure 1 This is a flow chart of the control algorithm interface of an embodiment of the present invention;

[0032] Figure 2 It is a flow chart of a method for implementing parallel collaborative simulation of Matlab and Abaqus according to an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the position arrangement of the titanium alloy flat plate radiation test sensor according to an embodiment of the present invention;

[0034] Figure 4 It is a schematic diagram comparing the temperature response curve of the model after the steady-state test debugging of the embodiment of the present invention with the test;

[0035] Figure 5 This is a schematic diagram of PI control simulation according to an embodiment of the present invention;

[0036] Figure 6Schematic diagram of control voltage comparison between simulation and experiment of an embodiment of the present invention. DETAILED DESCRIPTION

[0037] The preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not used to limit the scope of the present invention.

[0038] In the description of the embodiments of the present invention, it should be noted that, unless otherwise clearly specified and limited, the term "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection or an integral connection, a mechanical connection, an electrical connection, a direct connection, or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0039] The terms "top", "bottom", "above", "lower", and "on" used throughout the description are relative to the relative positions of components of a device, such as the relative positions of the top and bottom substrates within a device. It is understood that devices are multifunctional regardless of their orientation in space.

[0040] Example 1

[0041] An embodiment of the present invention discloses a quartz lamp radiation heating virtual test method, which uses computer simulation technology to virtually debug the heater design and control system parameter design of the aircraft whole machine or component thermal test, and can estimate the thermal response parameters of the structure surface, control the matching of input and output conditions, and ensure the smooth completion of the thermal test. Specifically, it includes the following steps:

[0042] Step 1: Build a simulation model of the heating control system:

[0043] In this embodiment, the simulation of the heating control system is implemented in Matlab, and Matlab\Simulink is used to build a simulation model of the heating control system.

[0044] In this embodiment, the input of the simulation model of the heating control system includes the expected surface temperature of the test piece, the control parameters, and the surface temperature of the test piece calculated in real time by Abaqus. The output of the simulation model of the heating control system is the heater power, such as Figure 1 Show.

[0045] In this embodiment, the control model includes PID control, fuzzy control or fuzzy adaptive PID control.

[0046] Among them, PID control parameters include: P-proportional gain; I-integral gain; D-differential gain; fuzzy control parameters include: error coefficient, error change rate coefficient and output coefficient; fuzzy adaptive PID control adjusts the control parameters of PID through fuzzy control, so its control parameters include both PID control parameters and fuzzy control parameters.

[0047] In this embodiment, the PID control needs to set one or more of the following based on the selected control type:

[0048] P control: only need to input proportional control parameter P;

[0049] PI control: You need to input the proportional control parameter P and the integral control parameter I;

[0050] PID control: You need to input the proportional control parameter P, integral control parameter I, and differential control parameter D.

[0051] Step 2: Establish a simulation model for test piece heating calculation:

[0052] The simulation model of the test piece heating calculation includes the time-varying heat source loading of the quartz lamp heating system and the thermal response process of the test piece. The simulation of the test piece heating calculation is completed in the finite element software Abaqus. The quartz lamp power comes from the heater power signal output by Matlab in step 1, which is converted into the quartz lamp temperature through the Abaqus subroutine. A cavity radiation model is established in Abaqus. At the same time, natural convection heat transfer is considered to calculate the temperature of the surface of the test piece. The temperature of the response point is written into an external shared file through a subroutine for the Matlab control module to call.

[0053] Step 3: Establish real-time data exchange between Matlab and Abaqus:

[0054] Construct a system simulation environment that combines Matlab and Abaqus, and use a parallel approach to achieve real-time data transfer between the two. Parallel system simulation includes multiple shared data files, which include data that need to be transferred to each other and related flags that control access to data files. The flags are used to control the alternating access of Matlab\Simulink and Abaqus to the data that needs to be transferred. Abaqus implements access to shared data files through the subroutine uampj, and Matlab\Simulink implements it through the S function. A total of 4 flags are set, and the flags are 0 or 1. The operations performed by different combinations are shown in Figure 2 Matlab and Abaqus read the flag file and perform corresponding operations according to the flag information.

[0055] Step 4: Perform thermal environment test on the test piece:

[0056] After the simulation model is established in Matlab and Abaqus, the corresponding parameters are set in the simulation model for the test piece to be tested, and a formal thermal environment test is carried out, which specifically includes the following steps:

[0057] Step 4.1: Enter the heater resistance in Abaqus.

[0058] Step 4.2: Establish the test model of the quartz lamp assembly and the test piece, and generate the Abaqus calculation master file;

[0059] When building a quartz lamp group model, use the plane heat transfer shell unit DS4 to build the model according to the length and width of the filament, and place it according to the test position. The units and nodes of each lamp group are set up as a set, and the units and nodes of all lamp groups are set up as a set.

[0060] In order to facilitate the rapid processing of the program, the name of the quartz lamp group is defined in an agreed manner. The temperature of the heat load point is given by the control program with electric power, which is converted into node temperature through the finite element real-time data transfer subroutine (UAMPJ) and passed to the finite element program to calculate the temperature of the test area.

[0061] When establishing the test piece model, the plane heat transfer shell unit DS4 is used to establish the grid model according to the actual geometric structure of the test piece, and a control point is taken in each heated area to monitor its temperature.

[0062] In order to facilitate the rapid processing of the program, the test piece set name is defined in an agreed manner. The serial number of each monitoring temperature response point of the test piece is consistent with the serial number of the lamp group heating zone. For example, ThermalResponseN003 is mainly heated by the third heating zone, and the rest are similar.

[0063] Create a property card to specify the element thickness and material for the test piece surface.

[0064] Create material cards and specify the material's specific heat, density, and thermal conductivity;

[0065] Step 4.3: Perform thermal environment test system identification in Matlab to obtain the transfer function of the system. The required data can be existing data or data calculated by Abaqus. The specific input data is the heater power, and the output data is the surface temperature of the test piece.

[0066] Step 4.4: Select the control type. If it is PID related control, the PID control parameters can be generated according to the system transfer function obtained in step 5.3;

[0067] Control type selection logic:

[0068] For basically linear systems, use PID control or fuzzy adaptive PID control, and for nonlinear systems, use fuzzy control. Specifically for quartz lamp radiation heating systems, if it is multi-zone zone heating, if the heating zone is obviously affected by the quartz lamps outside the heating zone, it may introduce strong nonlinearity. Fuzzy control or fuzzy adaptive PID control is preferred. If the heating zone is basically not affected by the quartz lamps outside the heating zone, PID control is preferred. If it is impossible to confirm in advance whether the heating zone is obviously affected by the quartz lamps outside the heating zone, PID control (with the highest control accuracy) can be used first, and then based on the actual control effect, confirm whether to switch to fuzzy control or fuzzy adaptive PID control.

[0069] Step 4.5: Import the expected test piece surface temperature, set the virtual test time, and start the simulation calculation. During the calculation process, the fuselage temperature curve, expected temperature curve, and heater power curve can be displayed in real time.

[0070] The present invention provides a quartz lamp radiation heating virtual test method, which realizes the quartz lamp thermal environment virtual test through the Matlab\Simulink and Abaqus collaborative simulation scheme. The simulation of the heating control system is realized in Matlab, and the simulation model of the heating control system is built using Matlab\Simulink. The input of the simulation model of the heating control system includes the expected temperature of the fuselage surface, the control parameters, and the fuselage surface temperature calculated in real time by Abaqus; the time-varying heat source loading of the quartz lamp heating system and the thermal response process of the test piece are completed in the finite element software Abaqus, and the quartz lamp power comes from the heater power signal output by Matlab, which is converted into the quartz lamp temperature through the Abaqus subroutine. A cavity radiation model is established in Abaqus, and natural convection heat transfer is considered at the same time. The temperature of the test piece surface is calculated, and the temperature of the response point is written into an external shared file through a subroutine for the Matlab control module to call; the system simulation environment combining Matlab and Abaqus uses a parallel method to realize the real-time data transmission between the two.

[0071] The quartz lamp radiation heating virtual test method of the present invention uses computer simulation technology to virtually debug the heater design and control system parameter design of the test piece thermal test, which can estimate the thermal response parameters of the structure surface, control the matching of input and output conditions, and ensure the smooth completion of the thermal test. The invention has a predictive and guiding role in the thermal environment ground simulation test, can reduce the test cost, shorten the test cycle, and can also achieve thermal environment simulation beyond the existing thermal environment ground simulation capabilities, providing a basis for the development of models, thereby accelerating the model development progress, improving the model product quality, and reducing the model development cost.

[0072] Example 2

[0073] A specific embodiment of the present invention discloses a virtual test method for quartz lamp radiation heating of a titanium alloy plate, and the virtual test method for quartz lamp radiation heating of Example 1 is adopted.

[0074] Specifically, the experiment used a group of quartz lamps to heat the titanium alloy plate, and a total of 9 temperature sensors were installed on the titanium alloy plate, such as Figure 3 Two groups of tests are carried out: steady-state test and transient test.

[0075] (1) Steady-state test

[0076] Keep the heater power basically unchanged and observe the temperature response on the titanium alloy plate. Use the results of the steady-state test to debug the model, mainly adjusting the surface radiation coefficient and the convection heat transfer coefficient. The steady-state calculation uses a heater power of 4600 watts and a resistance of 4.55 ohms. By adjusting the radiation emissivity and convection heat transfer coefficient, the calculated temperature can be well matched with the test temperature, such as Figure 4 shown.

[0077] Specific process of steady-state test:

[0078] Step 1: Create a titanium alloy plate and heater model, such as Figure 3 As shown;

[0079] Step 2: Simulate the heat transfer process with a heater power of 4600 watts and a resistance of 4.55 ohms. Adjust the radiation emissivity and convection heat transfer coefficient so that the calculated temperature matches the test temperature.

[0080] (2) Transient test

[0081] Set a set of desired temperatures for titanium alloy plates, and use PI feedback control to adjust the heater power in real time to control the surface temperature of the titanium alloy plates. Use the debugged model to simulate closed-loop PI control, and the PI parameters are consistent with the experiment (P = 5, I = 40). The simulation shows that the control parameters can well control the temperature of the titanium alloy plates, such as Figure 5 As shown, there is a certain gap between the control voltage obtained by simulation and the control voltage of the experiment, such as Figure 6 As shown in the figure, the control voltage obtained by simulation is higher than the experimental control voltage. The reason for this error may be the spatial and temporal changes in the convection heat transfer coefficient (a constant in the simulation). On the other hand, the voltage data measured in the experiment also has a large error (+ / -10%). From the above, it can be seen that the quartz lamp heating model was tested and compared. The results show that although the results have a certain error with the experiment, their accuracy is sufficient to verify the control parameters and heater design.

[0082] After the simulation model is established in Matlab and Abaqus, the corresponding parameters are set in the simulation model for the test piece to be tested, and a formal thermal environment test is carried out, which specifically includes the following steps:

[0083] Step 1: Enter the heater resistance in Abaqus;

[0084] Step 2: Establish the test model of the quartz lamp assembly and the test piece, and generate the Abaqus calculation master file;

[0085] When building a quartz lamp group model, use the plane heat transfer shell unit DS4 to build the model according to the length and width of the filament, and place it correctly according to the test position. Create a set of units and nodes for each lamp group, and a set of units and nodes for all lamp groups.

[0086] The temperature of the heat load point is given by the control program as electric power, which is converted into node temperature through the finite element real-time data transfer subroutine (UAMPJ) and transmitted to the finite element program to calculate the temperature of the test area.

[0087] When establishing the test piece model, the plane heat transfer shell unit DS4 is used to establish the grid model according to the actual geometric structure of the test piece, and a control point is taken to monitor its temperature.

[0088] Create a property card to specify the element thickness and material for the test piece surface.

[0089] Create material cards and specify the material's specific heat, density, and thermal conductivity;

[0090] Step 3: Select the control type as PI control, P=5, I=40;

[0091] Step 4: Import the expected test piece surface temperature, set the virtual test time, and start the simulation calculation. During the calculation process, the fuselage temperature curve, expected temperature curve, and heater power curve can be displayed in real time. The heater control voltage change curve can be obtained through the heater power curve.

[0092] Step 5: Compare the control voltage change curve obtained from the virtual test with the control voltage change curve from the physical test.

[0093] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

Claims

1. A virtual test method for quartz lamp radiation heating, characterized in that: The following steps are involved: Step 1: Establish a simulation model of the heating control system. The simulation of the heating control system is implemented in Matlab. Matlab\Simulink is used to build the simulation model of the heating control system. The input of the simulation model of the heating control system includes the expected surface temperature of the test piece, the control parameters, and the surface temperature of the test piece calculated in real time by Abaqus. The output of the simulation model of the heating control system is the heater power. Step 2: Establish a simulation model for the heating calculation of the test piece; wherein, the simulation model for the heating calculation of the test piece includes the time-varying heat source loading of the quartz lamp heating system and the thermal response process of the test piece. The simulation of the heating calculation of the test piece is completed in the finite element software Abaqus. The quartz lamp power comes from the heater power signal output by Matlab in step 1, which is converted into the quartz lamp temperature through the Abaqus subroutine. A cavity radiation model is established in Abaqus. Natural convection heat transfer is considered at the same time. The temperature of the surface of the test piece is calculated, and the temperature of the response point is written into an external shared file through a subroutine for the Matlab control module to call. Step 3: Establish real-time data exchange between Matlab and Abaqus; build a system simulation environment combining Matlab and Abaqus, and use parallel methods to realize real-time data transmission between the two; parallel system simulation includes multiple shared data files, and the shared data files include data that need to be transmitted to each other and related flags that control access to data files; control the alternating access of Matlab\Simulink and Abaqus to the data that needs to be transmitted through flags; Abaqus implements access to shared data files through the subroutine uamp, and Matlab\Simulink implements it through the S function; set 4 flags in total, the flags are 0 or 1, Matlab and Abaqus read the flag files, and perform real-time data exchange according to the flag information; Step 4: Conduct thermal environment test on the test piece; Step 4.1: Enter the heater resistance in Abaqus. Step 4.2: Establish the test model of the quartz lamp assembly and the test piece, and generate the Abaqus calculation main file; when establishing the quartz lamp assembly model, use the plane heat transfer shell unit DS4 to establish the model according to the length and width of the filament. Specifically, place it according to the test position, and use the plane heat transfer shell unit DS4 to establish the grid model according to the actual geometric structure of the test piece. Take a control point in each heated area to monitor its temperature; Step 4.3: Perform thermal environment test system identification in Matlab to obtain the transfer function of the system. The required data are existing data or data calculated by Abaqus. The input data is the heater power, and the output data is the surface temperature of the test piece. Step 4.4: Select the control type; If the quartz lamp radiation heating system is multi-zone zone heating, if the heating zone is obviously affected by the quartz lamps outside the heating zone, select fuzzy control or fuzzy adaptive PID control; if the heating zone is basically not affected by the quartz lamps outside the heating zone, select PID control; if it is impossible to confirm in advance whether the heating zone is obviously affected by the quartz lamps outside the heating zone, use PID control first, and confirm whether to switch to fuzzy control or fuzzy adaptive PID control based on the actual control effect; If it is PID related control, generate PID control parameters according to the system transfer function obtained in step 4.3; Step 4.5: Import the expected test piece surface temperature, set the virtual test time, and start the simulation calculation.

2. A virtual test method for quartz lamp radiation heating of a titanium alloy plate, characterized in that: The test method described in claim 1 includes a steady-state test and a transient test.

3. The quartz lamp radiation heating virtual test method of the titanium alloy flat plate according to claim 2 is characterized in that: In transient tests, a set of desired temperatures is set, and PI feedback control is used to adjust the heater power in real time to achieve control of the test piece surface temperature.

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